Conduit insert for optical fiber cable

ABSTRACT

A flexible innerduct structure is configured to contain a cable within a conduit. The innerduct structure includes a pair of adjacent strip-shaped layers of flexible material that are joined along their longitudinal edges to define a channel through which the cable can extend longitudinally through the innerduct structure between the layers. The adjacent layers have differing widths between their longitudinal edges, whereby the wider layer bulges away from the narrower layer to impart an open configuration to the channel. Other features of the innerduct structure relate to the material of which it is formed. Such features includes the structure of the material, such as a woven structure, and further include properties such as melting point, tensile strength, elongation, coefficient of friction, crimp resistance and compression recovery.

RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 10/625,008, filed Jul. 23, 2003, issued as U.S. Pat. No.7,085,455; which is a continuation of U.S. patent application Ser. No.10/354,869, now issued as U.S. Pat. No. 6,671,440; which is acontinuation of U.S. patent application Ser. No. 10/138,740, filed May2, 2002, now abandoned; which is a continuation of U.S. patentapplication Ser. No. 09/928,054, filed Aug. 10, 2001, now issued as U.S.Pat. No. 6,421,485; which is a continuation of U.S. patent applicationSer. No. 09/400,778, filed Sep. 22, 1999, now issued as U.S. Pat. No.6,304,698.

BACKGROUND OF THE INVENTION

The present invention generally relates to tubular conduit of the typethat might be employed for the housing of underground cables, such asfiber optic cable, coaxial cable, or the like. More particularly, thepresent invention relates to a partitioning device, which may beinserted into such a conduit such that the conduit is divided intoseparate areas. Specifically, the present invention is directed towardan elongated partitioning device which is flexible, such that it may beinserted into a conduit which is already in place, which may alreadyhave at least one cable positioned therein, and which may have turns,bends, or the like therein.

Cable, such as fiber optic communication cable, is often providedunderground in great lengths, and may even extend for many miles. It isknown in the art to bury the cable in the ground so that the area aboveground is not cluttered with the cable and its respective supportapparatus. Furthermore, by positioning the cable underground, it is moreprotected from the weather and other potentially damaging circumstances.

It is also known in the cable art to position the cable within a conduitin order to more fully protect the cable in the ground. The conduit isoften formed from lengths of polyvinyl chloride tubing or the like,which is laid in the ground. A rope is then blown through the conduit,and the rope in turn is attached to one of the communication cables. Bypulling the rope, the cable is drawn through the conduit. Once in placewithin the conduit, the cable is protected from damage which may becaused by weather, water and the like.

It has been found that certain rodents will sometimes gnaw through anunderground conduit. Hence, much underground conduit is employed whichhas a diameter of two inches or more, which is large enough to impededamage from most rodents. While such conduit provides excellentprotection for communication cable, there is also much unused or “dead”space within such a conduit. With the advent of fiber optic cables,which may be only a half-inch or less in diameter, there is even moredead space within an average conduit.

When a conduit is in place, it may be subsequently desired to run asecond communications cable at the same location. As such, it would bedesirable from a cost and time standpoint to make use of the dead spacewithin an existing conduit, rather than lay a new length of conduit.However, it has been found that it is difficult to merely insert asecond cable into a conduit which already contains a first cable. When arope is blown into a conduit already containing a cable, or a secondcable is “snaked” through the conduit, they are often impeded by thefirst cable, making it impossible to insert the second cable.

It has been suggested to provide a divider to be inserted into a conduitin order to separate the conduit into discrete sections, thus makinginsertion of the second cable easier. A problem has been encountered inthat when conduit is placed over long distances, undulations willinvariably occur therein. Also, planned curves, such as at underpassesor the like, will often be encountered rendering the placement of knowndividers therein difficult, if not impossible.

A need exists therefore for a device to separate or partition a conduit,such as an underground communication cable conduit, into discretesections. The device must be capable of being inserted into a conduitthat is already in place, which may undulate over many miles, and whichmay have sharp turns therein. A need also exists for a partitioningdevice which will provide for improved use of the space within aconduit.

SUMMARY OF THE INVENTION

The present invention comprises a flexible innerduct structureconfigured to contain a cable within a conduit. The innerduct structureincludes a pair of adjacent strip-shaped layers of flexible materialthat are joined along their longitudinal edges to define a channelthrough which the cable can extend longitudinally through the innerductstructure between the layers. In accordance with a principal feature ofthe invention, the adjacent layers have differing widths between theirlongitudinal edges, whereby the wider layer bulges away from thenarrower layer to impart an open configuration to the channel.

Other principal features of the invention relate to the material ofwhich the innerduct structure is formed. Such features include thestructure of the material, such as a woven structure, and furtherinclude properties such as melting point, tensile strength, elongation,coefficient of friction, crimp resistance and compression recovery.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention shall become apparent from the description which follows,in view of the drawings in which:

FIG. 1 is an isometric view of a conduit insert apparatus comprising afirst embodiment of the present invention;

FIG. 2 is a cross-sectional view of the apparatus of FIG. 1;

FIG. 3 is an isometric showing the apparatus of FIG. 1 within a conduit;

FIG. 4 is a cross-sectional view of an apparatus comprising a secondembodiment of the invention;

FIG. 5 is a partial view of an optical fiber cable used in accordancewith the invention;

FIG. 6 is a schematic view of a strip of innerduct layer materialconstructed in accordance with the invention;

FIG. 7 schematically shows the apparatus of FIG. 4 on a test device; and

FIG. 8 is a schematic view of another strip of innerduct layer materialconstructed in accordance with the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to the drawings, the reference number 10 represents aninsert, which may be referred to as an innerduct, to be inserted in anoptical fiber cable conduit 12. As shown in FIG. 3, a single innerduct10 is shown in a conduit 12, but it should be understood that multipleinnerducts like the innerduct 10 can be inserted in a conduit 12depending on the diameter of the conduit 12. For example, it iscontemplated that three such innerducts can be inserted in a 4″ diameterconduit providing nine channels for the insertion of fiber optic cable.

Each innerduct 10 defines of a plurality of channels 14 which are formedby interconnected layers of fabric 16, 18, 20 and 22, etc. In the firstembodiment of the invention each innerduct 10 has three channels 14formed by the above noted layers 16, 18, 20 and 22 which areinterconnected at their opposite longitudinal side edge portions byhaving the edge portions 25 of the lower layer 16 overlap the edgeportions of the other layers and, by sewing 24 or other suitable methodssuch as ultrasonic welding, connecting the layers 16, 18, 20 and 22together.

The fabric material preferably is soft and pliable, allowing theinnerduct 10 to be pulled through the conduit 12 without snagging orgenerating too much heat and also is diverse enough so that the cable inone channel 14 does not contact the cable in the next adjacent channel14. To this end the layers 16, 18, 20 and 22 in the first embodiment are100% plain woven nylon fabrics having a 520 denier monofilament in boththe warp and fill direction woven with a pick and end count of 38.5which, when finished, has a 40×40 pick and end count. The fabric has aweight of 6.0 oz. yd. It is understood that the monofilament denier canvary from 200-1000 denier and the pick and end could well be altered toprovide the desired cover to prevent contact of the fiber optic cables.

As stated above, the preferred yarn is 520 denier nylon 6 monofilamentbut another yarn, such as a 520 denier polyester, can be used so long asit has the desired characteristics.

The innerduct 10 is preferable constructed in the following manner. Thefabric layers 16, 18, 20 and 22 are initially woven in long wide shapesand are cut along the warp direction into strips with the center strip20 being the narrowest, the next adjacent strips 18 and 22 being wider,and the strip 16 being the widest so that when the strips 16-22 aremated and joined at their longitudinal edge portions the channels 14will be formed by the bulging of the wider strips 16,18 and 22. Afterthe strips 16, 18, 20 and 22 have been cut they are laid in between eachof the adjacent strips. Then the opposite longitudinal side edgeportions 25 of the lower strip 16 are folded over those of the otherstrips and are sewn to form the innerduct 10 shown in FIG. 1.

The innerduct 10 is manufactured in long lengths for insertion inpreviously installed conduits 12. Each layer 16-22 is formed in acorrespondingly long length by stitching or otherwise joining successivestrips of the fabric material together end to end. Pull lines 26, whichare preferably woven plastic tapes or plastic ropes, are tied to theoptical fiber cables (not shown) at one end and are pulled through thechannels 14 by grasping and pulling the lines 26 at the other end. Thepull lines 26 are preferably placed over the layers 16,18 and 20 beforethe layers 16-22 are overlapped and joined at their longitudinal edgeportions.

As shown for example in FIG. 3, a single innerduct 10 is inserted in aconduit 12 having an inner diameter of 4″. The strip-shaped fabric layer20 is 3″ wide, the layers 18 and 22 are 4″ wide, and the layer 16 is 6″wide. The width of the narrowest layer is thus less than the innerdiameter of the conduit 12. This helps to minimize frictional engagementof the innerduct 10 with the conduit 12 when the innerduct 10 is beingpulled through the conduit 12.

The above described innerduct is readily manufactured and provides astructure which allows optical fiber cables to be pulled through withoutsnagging or excessive heat build-up due to friction and does not allowcontact or alternation losses between adjacent fiber optic cables inother channels of the insert.

A flexible innerduct structure 100 comprising a second embodiment of theinvention is shown in FIG. 4. Like the innerduct structure 10 in thefirst embodiment, the innerduct structure 100 in the second embodimentcomprises strip-shaped layers of flexible woven material 102, 104, 106and 108 that are joined along their longitudinal edge portions 110, 112,114 and 116, respectively, by stitching 118. Each pair of adjacentlayers defines a respective cable channel 121, 123 or 125. In accordancewith the invention, the layers in each pair have differing widthsbetween their longitudinal edges such that the wider layer in the pairbulges away from the narrower layer. This imparts open configurations tothe channels 121, 123 or 125.

As in the innerduct 10, the open configurations of the channels 121, 123and 125 in the innerduct 100 facilitate insertion of cableslongitudinally through the channels 121, 123 and 125 by the use ofrespective pull lines 131, 133 and 135. This is because the spacingbetween the layers 102-108 helps to prevent them from being pulled alongwith the cables, and thus helps to prevent bunching-up of the innerduct100 within the conduit under the influence of the cable and pull lines131-135 moving longitudinally through the channels 121, 123 and 125.

As described above, the cross section of the innerduct 10 is defined byseparate strips of fabric material that are interconnected at theirlongitudinal edge portions to define overlying layers 16, 18, 20 and 22.As shown in FIG. 4, the overlying layers 102, 104, 106 and 108 of theinnerduct 100 also are interconnected at their longitudinal edgeportions, but are defined by folded sections of a single strip 140 offabric material. Two, three, four (FIG. 2) or more strips could be usedto define overlying layers in accordance with the invention. Each stripis one of a plurality of successive strips that are joined together endto end to provide the innerduct with a length that may extend, forexample, from three to four miles.

FIG. 5 is a schematic partial view of an optical fiber cable 150 to beinstalled in an innerduct constructed in accordance with the invention.The cable 150 includes a plastic sheath 152 containing a bundle ofoptical fibers 154. Preferably, each layer of the innerduct thatreceives the cable 150 is formed of a flexible plastic material that isspecified with reference to the plastic sheath 152 so as to have amelting temperature not lower than, and most preferably higher than, themelting temperature of the plastic sheathing material. This helps toensure that sliding friction will not cause the cable 150 to burnthrough the innerduct when the cable 150 is being pulled longitudinallythrough the innerduct. In accordance with this feature of the invention,the innerduct layers are preferably formed of nylon 6 so as to have amelting temperature of about 220 degrees C.

The resistance to cable burn-through can also be specified withreference to a pull line duct cutting test substantially similar to thetest known as the Bellcore pull line duct cutting test. In accordancewith this feature of the invention, the innerduct layer material ispreferably specified such that a 0.25 diameter polypropylene rope willnot burn through a test sample of the innerduct structure when pulledthrough the test sample at 100 feet per minute and 450 pounds tensionfor at least 90 seconds.

The innerduct layer material may further be specified with reference tothe material of which the pull lines are formed. In accordance with thisfeature of the invention, the layer material and the pull line materialpreferably have respective values of elongation percentage that aresubstantially equal for a given tensile load. If elongation of theinnerduct differs substantially from that of a pull line, one of thosestructures may lag relative to the other when they are pulled togetherthrough a conduit in which they are to be installed together. Theelongation percentages of the layer material and the pull line materialare preferably not greater than about 75 percent at a peak tensile load,i.e., just prior to tensile failure, and are preferably within the rangeof about 15 to about 60 percent. A more preferred range extends fromabout 25 to about 40 percent. For example, nylon 6 is a preferredmaterial and has an elongation of about 40 percent at a peak tensileload. Polyester is another preferred material and has an elongation ofabout 25 percent at a peak tensile load.

Other features of the invention relate to the tensile strength of theinnerduct layer material. In an innerduct constructed in accordance withthe invention, each layer preferably has a longitudinal tensile strengthof at least about 12.5 pounds per inch of width. The longitudinaltensile strength of each layer may be within the range of about 12.5 toabout 300 pounds per inch of width, and more preferably is within therange of about 50 to about 250 pounds per inch of width. However, thelongitudinal tensile strength of each layer is most preferably withinthe range of about 100 to about 200 pounds per inch of width. Forexample, each layer 102, 104, 106 and 108 in the innerduct 100 may beformed of a woven fabric having both warp and fill yarns formed of nylon6, with a longitudinal tensile strength of about 150 pounds per inch ofwidth.

The interconnected layers should together provide the innerductstructure, as a whole, with a longitudinal tensile strength of at leastabout 90 pounds, but may provide a longitudinal tensile strength withinthe range of about 50 to about 5,000 pounds. A more preferred range isfrom about 125 to 4,500 pounds, and a range of about 1,250 to about4,000 pounds is most preferable.

Additional features of the invention can be described with reference toFIG. 6. Specifically, FIG. 6 is a schematic view of a strip 160 of woveninnerduct fabric material for use in accordance with the invention. Thestrip has warp yarns 162 extending along its length and has fill yarns164 extending across its width. The fill yarns 164 are flexible but havea degree of rigidity or a resistance to crimping that helps the widerlayers of the innerduct to retain their bulged condition relative to theadjacent narrower layers, as shown for example in FIG. 4, without beingcrimped or creased inward toward the adjacent narrower layers. Suchcrimping or creasing is of less concern in the longitudinal direction ofthe layers. Therefore, the warp yarns 162 of FIG. 6 may have a crimpresistance that is less than the crimp resistance of the fill yarns 164.Such is the case in the preferred embodiment of the strip 160 in whichthe warp yarns 162 are formed of polyester, which has a first crimpresistance, and the fill yarns 164 are formed of nylon 6, which has asecond, greater crimp resistance.

Polyester is preferably used for the warp yarns 162 so as to minimizethe elongation differential with the pull lines, which also arepreferably formed of polyester.

The crimp resistance can be expressed in terms of the crimp recoveryangle. The crimp recovery angle is a measure of the degree to which asample of the material returns toward a flat unfolded condition afterhaving once been folded 180 degrees about a fold line in accordance withAATCC method 66. For example, a particular innerduct layer materialconstructed in accordance with the invention has heatset polyester warpyarns and nylon 6 fill yarns. That material was found to have a crimprecovery angle of 70 degrees in the warp direction and 135 degrees inthe fill direction. A similar material with greige polyester rather thanheatset polyester was found to have a crimp recovery angle of 50 degreesin the warp direction and 125 degrees in the fill direction. A materialhaving heat set polyester yarns in both the warp and fill directions wasfound to have a crimp recovery angle of 90 degrees in the warp directionand 75 degrees in the fill direction. A similar material having onlygreige nylon yarns in both the warp and fill directions is found to havea crimp recovery angle 130 degrees in the warp direction and 120 degreesin the fill direction.

The innerduct layer material should be rigid enough to resist collapsingupon itself or bunching up under the influence of the pull lines andcables, but also should be flexible enough to be pulled easily throughturns and undulation in the duct in which it is installed. The INDAIST90.3 test procedure is a method of determining the rigidity of theinnerduct layer material. In this procedure, a test sample of flexiblematerial is laid out over a slotted surface. A blade is then used toforce the material through the slot. The results are expressed in termsof the applied force. In accordance with the invention, a strip ofinnerduct layer material extending longitudinally across the slot willbe forced to bend along a transversely extending fold line. Such a stripwill preferably have rigidity test results within the range of about 950to about 1,750 grams. A strip of innerduct layer material extendingtransversely across the slot will be forced to bend about alongitudinally extending fold line, and will preferably have rigiditytest results within the range of about 150 to about 750 grams. The stripof innerduct layer material will thus have a lesser rigidity across itswidth. The correspondingly greater degree of flexibility across itswidth helps to avoid creasing and thereby helps the wider layers of theinnerduct to retain their bulged condition relative to the adjacentnarrower layers, as described above with reference to FIG. 4. Forexample, the strip 160 (FIG. 6) of woven innerduct fabric material hasfill yarns 164 that are formed of nylon 6. Such yarns are found to haverigidity test results within the range of about 350 to about 550 grams.The warp yarns 162 are formed of polyester. Such yarns are found to haverigidity test results within the range of about 1,250 to about 1,450grams.

The coefficient of friction also can be specified for the innerductlayer material in accordance with the invention. In accordance with thisfeature of the invention, the innerduct layer material preferably has adry static coefficient of friction, based on high density polyethyleneon the material with a longitudinal line of action, within the range ofabout 0.010 to about 0.500. This range is more preferably from about0.025 to about 0.250, and is preferably from about 0.035 to about 0.100.For example, a woven innerduct layer having polyester warp yarns andnylon 6 fill yarns was found to have a dry static coefficient offriction, based on high density polyethylene on the material with alongitudinal line of action, of 0.064. A similar material having heatset polyester warp yarns had a corresponding coefficient of friction of0.073. A material having heat set polyester yarns in both the warp andfill directions had a corresponding coefficient of friction of 0.090,and a material having nylon 6 greige yarn in both the warp and filldirections had a corresponding coefficient of friction of 0.067. Thesecoefficients of friction differed for transversely directed lines ofaction on the four foregoing materials and were, respectively, 0.085,0.088, 0.110, and 0.110. The dynamic or sliding coefficients of frictionfor these materials, again based on high density polyethylene on thematerial with a longitudinal line of action, were found to be 0.063,0.56, 0.058, and 0.049, respectively. The transverse counterparts tothese dynamic values were 0.064, 0.067, 0.078, and 0.075, respectively.Although these tested values of sliding coefficient of friction are mostpreferred, the invention comprises broader ranges such as the range fromabout 0.0050 to about 0.1250, as well as an intermediate range of about0.0075 to about 0.0625, and a narrower range of about 0.0100 to about0.0250.

Additional features of the invention relate to the open configurationsof the channels in the innerduct structures. Preferably, in addition tothe differing widths of the adjacent layers, the invention furthercomprises a material property of the layers that contributes to the openconfigurations of the channels defined by and between the layers. Thismaterial property of the layers is a spring-like resilience that enablesthe innerduct structure to maintain a freestanding condition such as,for example, the condition in which the innerduct structure 100 is shownin FIG. 7. When the innerduct 100 is fully flattened against the surface200 by an actuator 202 under the influence of an applied test force F,it will preferably rebound fully or substantially fully to its originalfreestanding condition as the force F is relieved upon retraction of theactuator 202. By “fully flattened” it is meant that the wider layers104, 106 and 108 are deflected toward and against the narrowest layer102 until the applied test force F reaches a peak level at which nofurther compression will occur without damage to the innerduct 100. Thisfully flattened condition will include folds between overlapping pliesof the wider layers 104, 106 and 108. Preferably, the innerduct 100, oranother innerduct constructed in accordance with the invention, will notundergo a next subsequent compression in the same manner under theinfluence of a peak applied test force that is less than about 85 to 100percent of the previous peak applied test force. This indicates thecorrespondingly high degree to which the innerduct tends to retain anopen configuration for passage of cables through the cable channels.

FIG. 8 is a view similar to FIG. 6 showing an alternative strip 200 ofinnerduct layer material constructed in accordance with the presentinvention. Like the strip 160 shown in FIG. 6, the strip 200 comprises awoven structure having warp yarns 202 and fill yarns 204. The strip 200further comprises a barrier 206 that blocks air from flowing through thestrip 200 between the warp yarns 202 and the fill yarns 204. Suchimpervious strips enable a cable to be blown through the innerductstructure without a loss of pneumatic pressure that could otherwiseresult from the passage of air outward through layers.

Impervious strips could be used to define all of the layers of theinnerduct structure, but would more preferably be used to define theoutermost layers of the innerduct structure. For example, a pair ofstrips like the strip 200 could be used to define the outermost layers16 and 22 of the innerduct structure 10 described above. A single striplike the strip 200 could be used to define all of the layers 102-108 ofthe innerduct structure 100 described above. In the embodiment shown inFIG. 8, the barrier 206 is a thin layer of plastic material that isbonded to the yarns 202 and 204 in a heat lamination process. If aplastic air barrier like the layer 206 is included in the innerductstructure at a location facing inward of a cable channel, it ispreferably formed of a plastic material having a melting temperaturethat is not less than the melting temperature of the plastic sheathingmaterial on the cable that is to be blown through the channel.

The invention has been described with reference to preferredembodiments. Those skilled in the art will perceive improvements,changes and modifications. Such improvements, changes and modificationsare intended to be within the scope of the claims.

1. Apparatus comprising: a conduit; a flexible structure positionedinside said conduit, said flexible structure comprising woven textilematerial adjoined in such a way as to define at least two longitudinalchannels that are configured to enclose and carry a cable, said flexiblestructure being formed to be resiliently biased toward an openconfiguration and to be readily collapsible in a transverse directionand further being comprised of warp yarns that provide said woventextile material with a first crimp recovery angle and fill yarns thatprovide said woven textile material with a second crimp recovery angle;means for pulling a cable into said structure; and at least one cablepositioned inside one of said longitudinal channels.
 2. The apparatus ofclaim 1, wherein said pulling means is selected from the groupconsisting of tape and rope.
 3. The apparatus set forth in claim 2,wherein said woven textile material and said pulling means haverespective values of elongation percentage that are substantially equalfor a given tensile load.
 4. The apparatus set forth in claim 3, whereinsaid elongation percentages are less than about 75 percent at peaktensile load.
 5. The apparatus set forth in claim 4, wherein saidelongation percentages are about 50 percent at peak tensile load.
 6. Theapparatus set forth in claim 1, wherein said yarns have a denier in therange of 200-1000 denier.
 7. The apparatus set forth in claim 1, whereinsaid flexible structure is formed from a plurality of strip-shapedlayers that are joined along their longitudinal edge portions to formsaid longitudinal channels.
 8. The apparatus set forth in claim 1,wherein said flexible structure is formed from a single sheet of saidtextile material.
 9. The apparatus set forth in claim 1, wherein saidcable has an outer plastic sheath material and said flexible structureis comprised of yarns having a melting temperature not lower than themelting temperature of the plastic sheath material of said cable. 10.The apparatus set forth in claim 1, wherein the width of said flexiblestructure is less than the inner diameter of said conduit.
 11. Theapparatus set forth in claim 1, wherein said longitudinal channels aredefined by stitching along the length thereof.
 12. The apparatus setforth in claim 1, wherein at least two flexible structures arepositioned in said conduit.
 13. The apparatus set forth in claim 1,wherein at least two cables are positioned in said longitudinal channelsof said flexible structure.
 14. The apparatus set forth in claim 1,wherein said flexible structure comprises polyester warp yarns and nylonfill yarns.